How to remove a manual window regulator?

[runderwo]

My driver's side door in my 91 XL is wrecked, so I got another door to replace it. Trouble is, the replacement door is power everything and the XL is manual. I changed out the lock and disconnected all the wiring, and I pulled the power motor out of the new door, but I'm stumped as to how to remove the manual reg on the old door to swap it over into the new door. I undid the one nut on the front, and felt around the back for hidden screws like the one behind the dimple on the power, but couldn't find anything. I drilled out all the rivets and nothing there either.

 

[Spdrcer34]

With all the Rivets out, it will drop out...I think there are 3 or 4.

Don't forget to remove the horizontal crossbar that bolts in using 2 gold 11mm nuts.

Ryan

 

[runderwo]

Yes, I removed that bar, it's just dangling there. When you say that the reg should just "drop out", can you be more specific what you mean? It's not budging! Is there something else I have to do to get it loose besides drill out the 3 rivets and remove the 1 nut above the crank handle shaft? There were not any fasteners hidden behind the rivets or anything. Is there anything hidden behind a dimple or something like on the power window?

 

[Spdrcer34]

There isn't anything out of the ordinary on the Manual Window Regulators....remove the plastic handle...drill the rivets, remove the nut, remove the cross bar...

Did you drill out (or unbolt) the rivets that hold the window to the regulator? There are access holes when the window is rolled down about 2". Drill them out.

Ryan

 

[runderwo]

Ah, now that might just be the "secret" I'm looking for! I'll look for those hidden rivets/bolts tomorrow when I've got light.

 

[runderwo]

I got the reg loose, it was just wedged or maybe stuck between the rivet holes and the stud. Enlarging the rivet holes slightly and tapping on the reg 'popped' it loose. Is there a specific kind of bolt to be used to install it where the rivets used to be or just use whatever works?

 

[Spdrcer34]

I replaces mine with 1/4" bolts, 3/4" long. Use Nylock Nuts.

Ryan

 

[runderwo]

I got the door all done, thanks a lot for your help.

Now for the hinge. I'll have to buy a new top hinge because it's bent about 20 degrees. Also, on the right hand hole in the hinge (the one behind the hinge bushing), there is a nut that screws onto a weird stud thing to clamp the hinge to the body. The stud thing has a "wing" on it that, together with a nut on the other side of the body panel, clamps it to the body. Then the nut for the hinge screws onto that. Problem is, that stud is sheared off, and the Ford dealer has no idea what I'm talking about because it's not in their diagram of the hinge.

 

[runderwo]

I replaced it by taking the nut and a large washer and holding them on the other, hidden side while threading the bolt through the hinge on the visible side. So the fasteners are backwards, but it works anyway.

Now, I had to use several washers between the door and the lower hinge to make the door line up. Now, the door is lined up perfectly, but unfortunately, the soft "stop" in the lower hinge operates at the wrong position. It should "stop" between 3/4 and full open, but instead it "stops" between 1/4 open and closed. Is there any way to adjust this or am I just going to have to live with it?